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Factories of the Future
Industry 4.0 – The European Perspective
Luis Carneiro
INESC TEC, on behalf of EFFRA
Agenda
The importance of the manufacturing industry
EFFRA – The European Factories of the Future Research Association
EFFRA Strategic Roadmap 2020
EFFRA Roadmap 2020 and Industry 4.0
Examples of FOF projects
Future calls for proposals
Background
Manufacturing & Europe
How important is manufacturing?
Despite the continued fall-out from crisis,
manufacturing means a lot for Europe:
20 % Direct jobs
67 % Exports (673 billion €)
65 % Business R&D Expenditure
Manufacturing in Europe remains diverse
Importance of manufacturing now recognised
by EU and its member states...
....but also by Europe’s competitors
Development of more competitive &
sustainable industry needs support
=> ‘Factories of the Future’
Positive trade balance in:
Machinery
Transport equipment
(mainly cars, but also
trucks, trains etc)
Chemicals
Processed agricultural
products
Realising Industry 4.0 in Europe
Factories of the Future
The European Union’s pre-competitive,
collaborative programme for
manufacturing research & innovation
Launched in 2010
Factories of the Future is a contractual
public-private partnership
The EU & industry have committed to
support European research &
innovation
Funded through EU’s Horizon 2020
research & innovation programme
Budget: €1.15 billion
Strategic research agenda = Factories of the Future 2020
EFFRA
Europe’s Factories of the Future Association
Representing private side in ‘Factories of the
Future’ PPP
160 members (Large, SME, RTO etc.) from
across Europe
An experienced, enaged and motivated
community
Actively promotes Factories of the Future PPP &
projects
Collaborates closely with EC to develop strategic
research agenda (‘roadmap’)
Works with national & regional initiatives
www.effra.eu
Factories of the Future 2020
Strategic Roadmap
One document covering 2014-2020
Developed by EFFRA & through broad
public consultation
Identifies megatrends which drive structural
changes in manufacturing sectors
Establishes research priorities which will
allow industry to meet these challenges
Priorities focus on development, application
& integration of enablers & technologies
‘Factories of the Future’ call topics based
upon research priorities = industry relevant
Not static: we are developing the Roadmap
further
Factories of the Future 2020
2010 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 2026 2027Nr of
projects
Cumulative
total
FoF-2010 25 25
FoF-2011 36 61
FoF-2012 37 98
FoF-2013 53 151
FoF-2014 29 180
FoF-2015 28 208
FoF-2016 37 238
25 projects
36 projects
37 projects
53 projects
25 projects
25 projects
post-project impact &investments
post-project impact & investments
post-project impact & investments
post-project impact & investments
post-project impact & investments
post-project impact & investments
37 projects post-project impact &investments
FoF in figures
Factories of the Future cPPP: Progress
238 Projects to date.
> 1,500 organisations participating
High involvement of SMEs: 200+
Majority of projects feature demo
activities
700+ results have been reported on EFFRA
Innovation Portal
Close to the market exploitation of project
results
Project results enhancing existing products
Factories of the Future & EFFRA
Connecting National & Regional programmes
From FoF 2020 roadmap to Factories 4.0 & Beyond
Structural Changes
Digitalisation
‘Digitalisation’ will affect manufacturing in a
similar way as it is already happening to
communication and consumers markets
Roos, G. (2014). The constantly changing manufacturing context.
Chapter 1 in Advanced Manufacturing - Beyond The Production Line.
Committee for Economic Development of Australia (CEDA).
Structural Changes
Increased level of digitalisation
Factories of the Future
Factories 4.0
Factories of the Future
Inspiration? Benchmark?
…
© MRK-Systeme
• Additional skin: damping
• Tactile sensors
• Capacitive proximity sensors
• Slow down
• Stop with seamless continuation of tasks
afterwards (Category 2)
• Full stop (Category 0)
The Productive Robot Apprentice
• Compare robot ‘learning’ by master-
apprentice relationship. Master teaches by
demonstration.
• Apprentice watches actions and effects and
stores these in his knowledge base.
• While applying this new skill, the master
corrects the execution by refining the
experience.
• This loop is iterated until satisfied result is
obtained.
• Operation without safeguards : limited
velocity -> dual armed robot approach for
achieving required productivity
• Local mobility in the workplace.
30 April 2015 FoF impact workshop - Success story: SUPREME
SUstainable PREdictive Maintenance
for Manufacturing Equipment
• Industrial end-user (paper mill) : Condat
• Transfer and Dissemination : Cofely-Endel
• SME’s as solution provider :
• Orloga (Paper engineering)
• EC_Systems (CMS provider)
• Optimitive (Process optimization)
• Loy&Hutz (CMMS)
• R&D partners
• CETIM
• FhG-IPA
• Grenoble-INP
• CVUT
• adapt dynamically maintenance planning to the current
condition of critical components
an increase in the reliability and availability of the
production equipment and a decrease of the
maintenance costs,
• a decrease of the energy consumption with an optimized
operation of the machine.
Outcome
I-RAMP3
Factories of the Future: Demonstration
I-RAMP3
Factories of the Future: Demonstration
Cyber physical
solutions exemplified on
an e-vehicle assembly
line
50% Decrease of ramp-up time for joining technologies
90% Decrease of ramp-up time for specialized assembly systems
Network-enabled Devices -- NETDEVs
Real-time system
NETDEV
Device interface
NETDEV communication
Real-time communication
I-RAMP3 compatible communication
Intelligent extension of traditional devices, featured with
Self-description Self-connecting Self-awareness and self-adaptation Task driven operation High level communication
In the Demonstrators, NETDEVs for
Servo-presses, Welding controls, Sensors, Cell orchestration, Data collection, …
Impacts -- Examples
Virtual Simulation and Training of
Assembly and Service Processes
in Digital Factories
www.fortissimo-project.eu
Project Example
FORTISSIMOEnabling manufacturing SMEs to benefit from high performance-computing
cloud-based simulations
Project Example
MANUTELLIGENCE
www.manutelligence.eu
Consortium:
New tools to model, simulate, optimize and monitor planned and existing
manufacturing systems necessary to overcome the complexity of demand dictated,
personalized, customer-driven and knowledge-based proactive production
Digital systems are often…
• Large applications with many functions
• Difficult to use
• expensive
• Not crosslinked
• Difficult to integrate in Legacy Systems
• Not mobile
Engineering Apps (eApps) are in
comparison…
Small applications with few features,
available in many devices (Tablets, phones)
Highly specilized
Crosslinked
Easy to use
Apps4ame
Engineering Apps for advanced Manufacturing Engineering
Apps4ame – Hybrid Process Manager
Dashboard for holistic view of project
status
Real time monitoring and control of the
ongoing work activities
Totally integrated Knowledge and
Document Management
Technical integration with Windows and
MS-Office productivity tools, which are
widely used by project teams
Integrated communication / Messaging
along the process activities
Problem solving support - tickets
management integrated with all entities
Support to individual tasks management
Apps4ame - SmartObjects
• Local access to
information and
technical assistance
• Condition monitoring
• Alarms generation (early-
warnings)
• Rules creation
and
configuration
CLoud
platform
Smart Object
Midlleware
Scalable 4.0
Scalable automation for flexible production systems
29
Objective: Develop and demonstrate
a Scalable production system
framework, where:
• Robots are considered as a pool of
production resources
• Robots are plug-n-produce
production resources
• Robots integrate seamlessly with
the humans and the production
system and are a source of
flexibility
Scalable 4.0
30Considering sharing of Tasks between humans and robots,
health and safety, scalability, …
Factories of the Future: Factories 4.0 Recent Developments
Factories of the Future Conference 2016
Major gathering of experts to discuss
achievements of partnership
Opened by Commissioner for Digital Economy
& Society, Gunther Oettinger
Recognition of importance of industry 4.0
Projects showcased results & progress
Conference demonstrated work underway to
realise industry 4.0 with factory 4.0 at its heart
Factories 4.0 & Beyond working document
unveiled
Complement existing roadmap
2018, 2019 & 2020 Call Topics will be
based upon Factories 4.0 & Beyond
€ 85 million for the following topics:
FoF-06-2017: New product functionalities through advanced surface
manufacturing processes for mass production
FoF-07-2017: Integration of unconventional technologies for multi-
material processing into manufacturing systems
FoF-08-2017: In-line measurement and control for micro-/nano-
enabled high-volume manufacturing for enhanced reliability
FoF-09-2017: Novel design and predictive maintenance technologies
for increased operating life of production systems
FoF-10-2017: New technologies and life cycle management for
reconfigurable and reusable customised products
€ 33 million for the following topic:
FoF-12-2017: ICT Innovation for Manufacturing SMEs (I4MS)
Factories of the Future
Call 2017 (Open)
Factories of the Future: Call 2017 (Opens in 2016)
Online Brokerage Open
Online brokerage for Call 2017 is open on EFFRA’s Innovation
Portal www.effra.eu/portal
Upload an expression of interest in a call topic
Find potential project partners
Innovation Portal includes information on all ‘Factories of the
Future’ projects launched to date including information on project
consortia.
PPP Info Day on 14 October 2016 in Brussels
Factories of the Future: Key Tool
EFFRA Innovation Portal
www.effra.eu/portal
• for progress monitoring
• for sharing information among projects
• for promoting projects, results and
demonstrators to the wider community
• for portfolio management and analysing
coverage of FoF 2020 roadmap
• for supporting the further roadmapping
exercises
One reference resource…
